Elastomeric waterproofing and weatherproofing photovoltaic finishing method and system

ABSTRACT

The present invention is for a system and method of creating a continuous, seamless, waterproof, weatherproof, electrically generating surface that can be applied over a great variety of structural components. The method comprises coating the selected surface with a base elastomeric coating thus sealing holes, cracks and other surface imperfections. In one embodiment, the base elastomeric coating is allowed to dry and at least one photovoltaic module is placed on the base elastomeric coating by using another coat of elastomeric material applied to the underside surface of the photovoltaic module or on the surface of the base elastomeric coating where the photovoltaic module will be applied. Another layer of an elastomeric coating is applied covering the perimeter edges of the photovoltaic module creating a continuous, seamless, waterproof, weatherproof surface capable of generating electricity. Other embodiments include various strengthening elements to create durable, weatherproof surfaces with the photovoltaic modules integrated therein.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/682,163, filed Mar. 5, 2007 now allowed, which is acontinuation-in-part of U.S. patent application Ser. No. 11/533,752filed Sep. 20, 2006, which in turn claims priority to ProvisionalApplication Ser. No. 60/797,248, filed on May 3, 2006, 60/800,945, filedon May 17, 2006 and 60/808,704, filed on May 26, 2006, the completedisclosures of each of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

Shelter is a basic human necessity with caves and trees no doubt servingas the earliest form of protection from the elements. One importantfunction of a roof or wall is keeping rain or snow outside the dwelling.While caves served this purpose reasonably well, other structures provedmore difficult to weatherproof. Additionally, although modern buildingtechniques have overcome these problems, exterior surfaces still age andare subject to leaks. A leaking exterior surface can prematurely age anexisting structure and require extensive repairs or completereplacement. It is known to apply weatherproofing materials to exteriorsurfaces in an attempt to stop leaks and extend the life of thestructure.

Unlike the caves and tree houses of our ancestors, modern dwellingsrequire energy to keep them comfortable. In the past houses were heatedby means of a fire in fireplaces and stoves but today's houses are notonly heated but cooled keeping our homes and places of business at acomfortable temperature year-round. In the United States the cost ofenergy has traditionally been relatively low and our dwellings are keptcomfortable using a variety of energy sources such as natural gas,electricity, propane, fuel oil, kerosene, etc. As the cost of energyrises, interest in alternative energy sources has risen and becomeeconomically feasible in many cases. One area that is experiencing rapidgrowth due to technological advances in the field is the use ofphotovoltaic surfaces to generate electricity. Originally photovoltaicmodules tended to be heavy and fragile but today's photovoltaic modulesare thin, flexible and durable allowing them to be used in many moreapplications than in the past.

There is a need for a system that can weatherproof a surface as well asincorporating photovoltaic modules therein to create a durableweatherproof layer for either new construction or retrofits.

SUMMARY OF THE INVENTION

The present invention is for a system and method of creating acontinuous, seamless, waterproof, weatherproof, electrically generatingsurface that can be applied over a great variety of structuralcomponents. The method comprises coating the selected surface with abase elastomeric coating thus sealing holes, cracks and other surfaceimperfections. In one embodiment, the base elastomeric coating isallowed to dry and at least one photovoltaic module is placed on thebase elastomeric coating by using another coat of elastomeric materialapplied to the underside surface of the photovoltaic module or on thesurface of the base elastomeric coating where the photovoltaic modulewill be applied. Another layer of an elastomeric coating is appliedcovering the perimeter edges of the photovoltaic module creating acontinuous, seamless, waterproof, weatherproof surface capable ofgenerating electricity. Other embodiments include various strengtheningelements to create durable, weatherproof surfaces with the photovoltaicmodules integrated therein.

Other features and advantages of the instant invention will becomeapparent from the following description of the invention which refers tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a surface treated according to an embodiment ofthe present invention.

FIG. 2 is a top view showing the next step of the surface treatedaccording to an embodiment of the present invention.

FIG. 3 is a top view of a surface treated according to yet anotherembodiment of the present invention.

FIG. 4 is a side view of a structurally reinforced photovoltaic moduleaccording to an embodiment of the present invention.

FIG. 5 is a detailed view of the section shown in FIG. 4.

FIG. 6 is a side view of a structurally reinforced photovoltaic moduleaccording to another embodiment of the present invention.

FIG. 7 is a top view of a surface treated according to an embodiment ofthe present invention.

FIG. 8 is a cutaway view of a surface having a dual slope photovoltaicmodule according to an embodiment of the present invention.

FIG. 9 is a cutaway view of a surface portion having a thermallystabilized photovoltaic module according to an embodiment of the presentinvention.

FIG. 10 is a cutaway view of a surface portion having an insulatingmember integrated in a photovoltaic module according to an embodiment ofthe present invention.

FIG. 11 is a cutaway view of a corrugated surface treated according toan embodiment of the present invention.

FIG. 12 is a cutaway view of a corrugated surface having a thermallystabilized photovoltaic module according to an embodiment of the presentinvention.

FIG. 13 is a cutaway view of a corrugated surface having a thermallystabilized photovoltaic module according to another embodiment of thepresent invention.

FIG. 14 is a cutaway view of a surface treated according to anembodiment of the present invention.

FIG. 15 is a cutaway view of a surface having a thermally stabilizedphotovoltaic module according to an embodiment of the present invention.

FIG. 16 is a cutaway view that illustrates a step according to anembodiment of the present invention.

FIG. 17 is a cutaway view that illustrates a second step according to anembodiment of the present invention.

FIG. 18 is a cutaway view that illustrates a third step according to anembodiment of the present invention.

FIG. 19 is a cutaway view that illustrates a fourth step according to anembodiment of the present invention.

FIG. 20 is a cutaway view that illustrates a fifth step according to anembodiment of the present invention.

FIG. 21 is a cutaway view that illustrates the finished productaccording to an embodiment of the present invention.

FIG. 22 is a cutaway view of yet another step according to an embodimentof the present invention.

FIG. 23 is a cutaway view of yet another step according to an embodimentof the present invention.

FIG. 24 is a cutaway view of another step according to an embodiment ofthe present invention.

FIG. 25 is a cutaway view of a step according to an embodiment of thepresent invention.

FIG. 26 is a cutaway view of still another step according to anembodiment of the present invention.

FIG. 27 is a cutaway view of a step according an embodiment of thepresent invention.

FIG. 28 is a cutaway view of a step according to an embodiment of thepresent invention.

FIG. 29 is a cutaway view of a step according to an embodiment of thepresent invention.

FIG. 30 is a cutaway view of a surface having a single slopephotovoltaic module according to an embodiment of the present invention.

FIG. 31 is a cutaway view of a corrugated surface having a thermallystabilized photovoltaic module according to another embodiment of thepresent invention.

FIG. 32 is a cutaway view of an embodiment according to the presentinvention.

FIG. 33 is a cutaway view of another embodiment according to the presentinvention.

FIG. 34 is a cutaway view of yet another embodiment according to thepresent invention.

FIG. 35 is a cutaway view of still another embodiment according to thepresent invention.

FIG. 36 is a cutaway view of another embodiment according to the presentinvention.

FIG. 37 is a cutaway view of another embodiment according to the presentinvention.

FIG. 38 is a cutaway view of another embodiment according to the presentinvention.

FIG. 39 is a cutaway view of another embodiment according to the presentinvention.

FIG. 40 is a cutaway view of another embodiment according to the presentinvention.

FIG. 41 is a cutaway view of another embodiment according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to the drawings in which reference numerals referto like elements. The present invention is used to weatherproof mostkinds of surfaces such as but not limited to masonry, concrete block,tilt-wall, pre-cast forms, poured concrete, pre-stressed concrete, posttensioned concrete, cementitious, EIFS, corrugated panels, wood, androofing materials.

Referring now to FIGS. 1 and 2, a surface 10 is coated with anelastomeric base coat 12 to cover at least a portion of surface 10.Elastomeric base coat 12 covers cracks, holes and other surfaceimperfections thus rendering surface 10 impervious to rain, snow andother weathering effects. Next a photovoltaic module 14 is pressedagainst elastomeric base coat 12 before elastomeric base coat 12 setsup. Photovoltaic module 14 thus adheres to elastomeric base coat 12.Photovoltaic module 14 can be a flexible roll out module, semi-flexiblefan fold module or a semi-flexible or rigid flat module panel as isknown in the art.

Next, another elastomeric coat 15 is applied over elastomeric base coat12 and around the perimeter 16 of photovoltaic module 14 thus completelysealing photovoltaic module 14 and creating a continuous, seamless,waterproof and weatherproof surface capable of generating electricity.

According to another embodiment, FIG. 3 illustrates the presentinvention with the addition of a structural element 24 to increase thebonding and mechanical properties of photovoltaic module 28. Structuralelement 24 can be a fabric mesh such as a reinforced polyester mesh,flashing fabric, semi-flexible or rigid thin polymer, fiber orcementitious backerboard or other synthetic fabric as is known in theart. Structural element 24 may be factory applied to photovoltaic module28 or they may be field applied by the installation technician. Thepurpose of structural element 24 is to provide additional bonding andstability for photovoltaic module 28. As before, an elastomeric basecoat 22 is applied over a surface 20 to provide a weatherproof surface.Structural element 24, which is generally larger than photovoltaicmodule 28, is then placed against elastomeric base coat 22 while it isstill wet. If additional strength is needed, structural element 24 maybe placed over the entire surface 20. If sufficient elastomeric materialpenetrates structural element 24, then photovoltaic module 28 may beplaced directly on structural element 24 thus providing the necessarybonding. It may be desirable in some applications to apply moreelastomeric material over structural element 24 before placingphotovoltaic element 28 to ensure bonding. Then as discussed above,another elastomeric coat 26 is applied around the perimeter ofphotovoltaic element 28 providing a continuous, seamless, waterproof andweatherproof surface capable of generating electricity. In otherembodiments, photovoltaic element 28 may be supplied with a self stickadhesive or a field applied adhesive on a back surface to aid adhesion.

Referring now to FIGS. 4 and 5, an embodiment of the present inventionis shown utilizing mechanical structural element 40 to aid in securingphotovoltaic element 28 in addition to improving the bonding strength ofelastomeric base coat 22. Mechanical structural element 40 may be abolt, expander, anchor or any other suitable support element capable ofholding photovoltaic element 28 to surface 20 as is known in the art.Mechanical structural element 40 provides additional support especiallybefore elastomeric base coat 22 and another elastomeric coat 26 arefully cured. As can be seen in detail in FIG. 5, mechanical structuralelement 40 is also covered by elastomeric coat 26 thus providing acontinuous, seamless, waterproof and weatherproof surface completelysealing surface 20 as well as photovoltaic element 28.

FIG. 6 is basically the same as the embodiment shown in FIGS. 4 and 5with the addition of structural element 24 to provide a better bondingsurface as discussed above. Additionally, it is possible to place asloped insert (FIGS. 6 and 30) under photovoltaic element 28 to betteralign photovoltaic element 28 with the sun.

Referring now to FIG. 7, a surface 70 is shown having a plurality ofphotovoltaic elements 78. As discussed above, a first elastomeric basecoat 72 is applied over the entire surface to be treated, sealing andweatherproofing surface 70. Once surface 70 is coated with elastomericbase coat 72, photovoltaic elements 78 are set in place beforeelastomeric base coat 72 is dry thus bonding photovoltaic elements 78 tosurface 70. Once photovoltaic elements 78 have been placed, anotherelastomeric coat 76 is applied to the perimeter of each photovoltaicelement 78 thus providing a continuous, seamless, waterproof andweatherproof surface capable of generating electricity. Photovoltaicmodules 78 are electrically connected by means of a factory or onsitewiring system in either series, parallel or in combination ofseries/parallel connections to line conditioners, inverters, systemcontrollers, and system monitors to the building's power system foron-the-grid or off-the-grid application as is known in the art.

In another embodiment, first elastomeric base coat 72 is applied overthe entire surface to be treated and then allowed to dry. An additionalelastomeric coating (not shown) is applied to a lower surface ofphotovoltaic elements 78 or alternatively to a region corresponding toan area where photovoltaic elements 78 will be placed on surface 70 andthen photovoltaic elements 78 are placed thereon with the additionalelastomeric coating providing the necessary adhesion to anchorphotovoltaic elements 78. Alternatively, photovoltaic elements 78 may besupplied with a self stick adhesive coating (not shown) and a protectivebacking which is removed during installation. A field applied adhesive(not shown) may be used to apply module to the waterproofed surface 70prior to sealing photovoltaic module 78 with elastomeric coating 76. Inyet another embodiment, photovoltaic element 78 is factory supplied witha structural element (not shown) such as synthetic fabric or mesh toincrease the bonding properties therein.

Photovoltaic elements are more efficient when facing the sun. Whenphotovoltaic elements are mounted on a roof, solar efficiency changesduring the day due to the Earth's rotation. One solution to this problemis a sloped installation of the photovoltaic elements.

FIGS. 8 and 30 are examples of a dual slope installation (FIG. 8) and asingle slope installation (FIG. 30) respectively according to anembodiment of the present invention. A surface 82 is prepared byapplying an elastomeric base coat 87 over the entire surface to betreated. Next a dual slope insert 86 or a single slope insert 186 isapplied to elastomeric base coat 87 and elastomeric base coat 87 is alsoapplied over dual slope insert 86 or single slope insert 186. Nextphotovoltaic element 80 is applied to both sides of dual slope insert 86or to one side of single slope insert 186 and another elastomeric coat86 is applied to the perimeter of photovoltaic element 80 thus sealingand providing a continuous, seamless, waterproof and weatherproofsurface. Additionally, photovoltaic element 80 may be supplied withstructural elements (not shown) as discussed above. Typical insulativeinserts include synthetic fabrics and mesh, polyisocyanurate foam,expanded or extruded polystyrene foam, organic fiber, mineral composite,plastic polymer and fiberglass as well as others as is known in the art.

Photovoltaic elements are more efficient in a specific temperature rangeyet most climates vary greatly from season to season and even on a dailybasis. In order to increase efficiency, it is sometimes desirable tomount a liquid temperature regulating system to regulate the temperatureof the photovoltaic element. FIG. 9 is a cutaway view showing such aninstallation. Surface 90 is covered as before with elastomeric base coat92 and a tubing module 94 is placed against elastomeric base coat 92.Tubing module 94 is connected to a pumping system to control the flowand temperature of the liquid within the tubes as is known in the art.Another elastomeric layer 196 is applied over tubing module 94 furthersealing surface 90. A photovoltaic element 98 is placed over elastomericlayer 196 covering tubing module 94 thus regulating the temperaturethereof. An additional elastomeric coat 96 is applied around theperimeter of photovoltaic element 98 and the sides of tubing module 94thus providing a continuous, seamless, waterproof and weatherproofsurface capable of generating electricity. Additionally, the system canbe used in conjunction with solar water heating modules as is known inthe art to not only provide thermal regulation but additional energysavings by utilizing the heated water.

FIG. 10 illustrates a passive thermal regulating embodiment of thepresent invention. Surface 90 is coated with elastomeric base coat 92 asdiscussed above and an insulating insert 102 is applied. Anotherelastomeric layer 196 is applied over insulting insert 102 furthersealing surface 90. Typical insulative inserts include synthetic fabricsand mesh, polyisocyanurate foam, expanded or extruded polystyrene foam,organic fiber, mineral composite, plastic polymer and fiberglass as wellas others as is known in the art.

Photovoltaic element 98 is placed on top of elastomeric layer 196 whichcovers insulating insert 102. Again, another elastomeric coat 96 isapplied to the perimeter of photovoltaic element 98 and the sides ofinsulating insert 102 to provide a continuous, seamless, waterproof andweatherproof surface capable of generating electricity.

FIG. 11 shows the present invention as applied to a corrugated surface135 covering a substrate 130. An elastomeric base coat 120 is appliedover corrugated surface 135 to be treated. It should be noted thatelastomeric base coat 120 completely encapsulates seam fasteners 125thus eliminating a possible source of environmental exposure. Insulatedinsert 102 is placed on corrugated surface 135 between the corrugations.Insulated insert 102 is deformed to provide a level surface to mountphotovoltaic element 98 as is known in the art. Insulating insert 102 isbonded and sealed by means of another elastomeric coat 196. Photovoltaicelement 98 is placed on top of insulating insert 102 and anotherelastomeric coat 96 is applied around the perimeter of photovoltaicelement 98 thus providing a continuous, seamless, waterproof andweatherproof surface while also providing electricity. This isparticularly advantageous since corrugated surfaces often leak as theyage. As discussed above, a structural element (not shown) may be used toprovide further stability and enhance weatherproofing propertiestherein.

FIGS. 12 and 13 illustrate other embodiments of the present invention aspracticed on corrugated surfaces. The embodiment shown in FIG. 12utilizes a tubing module 104 mounted beneath photovoltaic element 98with another elastomeric layer 196. As discussed above, tubing module104 is connected to a pumping system (not shown) as is known in the art.This regulates the temperature of photovoltaic element 98 increasingefficiency. The embodiment illustrated in FIG. 13 also includes aninsulated insert 106 to further control temperature of photovoltaicelement 98 as described previously.

Referring to FIG. 31, an embodiment of the present invention applied toa corrugated surface is shown having a flat profile between thecorrugations and is coated with elastomeric base coat 120 over thesurface to be treated. Again, as discussed above, seam fasteners 125 arecovered by elastomeric base coat 120 to provide a continuous, seamless,waterproof and weatherproof surface. Photovoltaic element 98 may beplaced on elastomeric base coat 120 while it is still wet or elastomericbase coat 120 may be allowed to dry and then another elastomeric coat196 may be applied to either an area where photovoltaic element 98 willbe placed or applied directly to photovoltaic element 98 to bondphotovoltaic element 98 to the surface. Photovoltaic element 98 isplaced on top of insulating insert 102 and another elastomeric coat 96is applied around the perimeter of photovoltaic element 98 thusproviding a continuous, seamless, waterproof and weatherproof surfacewhile also providing electricity.

FIGS. 14 and 15 illustrate embodiments that utilize a flashing element110 to provide even more protection against water and water vaporintrusion. Flashing element 110 may be field applied by technicians ormay be factory applied to photovoltaic element 98. If field applied,elastomeric base coat 92 may be utilized to bond flashing element 110 tophotovoltaic element 98 as well as to surface 90. Flashing elements 110and 96 can be reinforced with an embedded synthetic fabric or mesh.Alternatively, any suitable adhesive may be utilized to bond flashingelement to elastomeric base coat 92. Again another elastomeric coat 96is applied around the perimeter of photovoltaic element 98 coveringflashing element 110 providing a continuous, seamless, waterproof,weatherproof surface capable of generating electricity.

FIGS. 16 through 21 illustrate an embodiment of a method according tothe present invention providing a continuous, seamless, waterproof,weatherproof surface capable of generating electricity. A surface 160 isprepared to receive an elastomeric base coat 165. If the presentinvention is practiced on an existing surface, it may be desirable toprepare the surface by power washing or otherwise cleaning debris andother environmental buildup. Elastomeric base coat 165 will covercracks, holes and other imperfections in surface 160. Additionally, dueto the properties of elastomeric base coat 165, the surface will gainstructural integrity and become impervious to weather related hazardssuch as hail, snow, rain and moisture and general weathering. In oneembodiment, a photovoltaic element 170 is placed against elastomericbase coat 165 while it is still wet to anchor photovoltaic element 170thereon. In another embodiment, elastomeric base coat 165 is allowed todry and then another elastomeric coat (not shown) is applied either toan area corresponding to the position where photovoltaic element 170will be placed or alternatively on a lower surface of photovoltaicelement 170. In some applications it may be desirable to utilize anadhesive backed photovoltaic element or a field applied adhesive (notshown) to provide further anchoring to photovoltaic element 170 as isknown in the art.

In the embodiment shown in FIG. 19, a mask 175 may be field applied ormay be provided by the manufacturer of photovoltaic element 170. Mask175 may be masking tape or other masking material and is used to protectthe surface of photovoltaic element 170 while applying anotherelastomeric coat 180. Another elastomeric coat 180 is applied toelastomeric base coat 165 and around the perimeter of photovoltaicelement 170 being careful not to extend past mask 175. Once elastomericcoat 180 is dry, mask 175 is removed completing the installation andproviding a continuous, seamless, waterproof and weatherproof surfacecapable of generating electricity. Elastomeric base coat 165 and anotherelastomeric coat 180 need not be the same material. For example,elastomeric base coat 165 may be optimized to provide excellent sealingand crack coverage while not providing sufficient UV protection. In suchan application, another elastomeric coat 180 may be optimized to providesuperior UV protection thus sealing the vulnerable elastomeric base coat165 underneath.

FIG. 22 illustrates an embodiment that includes adding structuralelement 200 to the process discussed above. Structural element 200 maybe a non-reinforced or reinforced polymer structure, polyester mesh orother synthetic fabric designed to increase the stability, mechanicalproperties and holding power of elastomeric materials. FIG. 23 showsphotovoltaic element 170 placed on top of structural element 200. FIG.24 shows mask 175 being applied to photovoltaic element 170. Next, FIG.25 shows another elastomeric coat 180 being applied on top of structuralelement 200 and photovoltaic element 170, thereby sealing structuralelement 200 and photovoltaic element 170 within. Mask 175 protectsphotovoltaic element 170 during installation. FIG. 26 shows thecompleted surface with mask 175 removed thus providing a continuous,seamless, waterproof, weatherproof surface capable of generatingelectricity.

FIG. 27 illustrates an embodiment with an additional flashing element225 either field installed or factory installed on photovoltaic element170. Mask 175 is either field applied or factory applied. In FIG. 28another elastomeric coat 180 is applied on top of elastomeric reinforcedflashing element 225 and photovoltaic element 170 thus sealing andprotecting photovoltaic element 170. In FIG. 29, mask 175 has beenremoved completing the installation to provide a continuous, seamless,waterproof, weatherproof surface capable of generating electricity.

Referring to FIG. 32, a structure 1000 is coated with an elastomericcoat 1200 and a photovoltaic element 1400 is placed against elastomericcoat 1200 to secure it therein. Elastomeric coat 1200 in conjunctionwith photovoltaic element 1400 provide a continuous, seamless,waterproof and weatherproof covering the part of structure 1000 coveredtherein.

Referring now to FIG. 33, an alternative embodiment is illustrated ashaving structure 1000 coated with a first elastomeric coat 1600. Next,elastomeric coat 1200 is applied on top of first elastomeric coat 1600and photovoltaic element 1400 is placed against elastomeric coat 1200.Elastomeric coat 1200 and first elastomeric coat 1600 may be the samematerial or they may be selected to be a different elastomeric coatingas discussed previously.

Now referring to FIG. 34, in another embodiment according to the presentinvention, structure 1000 is coated with first elastomeric coat 1600 andthen another elastomeric coat 1800 is applied at least underphotovoltaic element 1400 and then either while still wet or afterdrying, photovoltaic element 1400 is placed on elastomeric coat 1800 andelastomeric coat 1200 is applied around the perimeter of photovoltaicelement 1400 to provide a continuous, seamless, waterproof andweatherproof covering over the part of structure 1000 that is coveredtherein. Again as discussed above, elastomeric coats 1600, 1800 and 1200may all be the same material or a combination of elastomeric materialsselected to have specific properties such as heat resistance, low vaporpermeance, U.V. resistance or weathering properties, etc.

Reference is now made to FIG. 35 which shows structure 1000 havingphotovoltaic element 1400 applied directly therein using another layer2000 which may be an adhesive material such as a self-adhesive appliedto a lower surface of photovoltaic element 1400, a double-sided selfrelease tape that is applied either from the factory or in the fieldduring installation, a construction adhesive applied on site duringinstallation or even another elastomeric layer. The double-sided releasetape may be a reinforced fabric with an adhesive on both sides with eachside having a removable release film. Of course other kinds of adhesivematerials would be acceptable as is known in the art. Elastomeric coat1200 is then applied around the perimeter of photovoltaic element 1400as discussed above.

Reference is now made to FIG. 36 which shows structure 1000 havingphotovoltaic element 1400 applied on top of elastomeric coat 1600.Photovoltaic element 1400 is adhered to elastomeric coat 1600 withanother layer 2000 such as a self-adhesive applied to a lower surface ofphotovoltaic element 1400, a double-sided self release tape that isapplied either from the factory or in the field during installation,construction adhesive applied on site during installation or anotherelastomeric layer as discussed above. Elastomeric coat 1200 is thenapplied around the perimeter of photovoltaic element 1400 as discussedabove.

FIG. 37 illustrates the present invention as applied to structure 1000.Elastomeric coat 1600 is applied and then another layer 2000 is appliedunder photovoltaic element 1400 and elastomeric coat 1200 is appliedaround the perimeter as discussed above. A flashing 2200 is applied tothe seam between photovoltaic element 1400 and elastomeric coat 1200 toprovide extra protection. Flashing 2200 may be a fabric surfaced andfabric reinforced tape with either a polymer or metal film surface andmay have a self-adhesive surface. Flashing 2200 may be modified toensure adhesion when applied to surfaces that are difficult to coat suchas Teflon or other such materials.

FIG. 38 is identical to the embodiment shown in FIG. 37 with theaddition of another elastomeric coat 2400 over flashing 2200 to furtherseal the seam from the elements.

FIG. 39 illustrates another embodiment according to the presentinvention where elastomeric coat 1600 is applied over structure 1000 andthen another elastomeric coat 1800 is applied under photovoltaic element1400 to provide a continuous, seamless, waterproof and weatherproofcovering over the part of structure 1000 that is covered therein. Againas discussed above, elastomeric coats 1600 and 1800 may be the same ordifferent materials.

Now referring to FIG. 40, structure 1000 is coated with elastomeric coat1600 and then another elastomeric coat 1800 is applied at least under anarea under photovoltaic element 1400. An inter-ply element 1750 isapplied. Inter-ply element 1750 may be a fabric mesh, a polymer, metalfoil or combination therein. Inter-ply element 1750 functions asreinforcement, insulator and/or vapor barrier. In some applications, itmay be advantageous to include even more inter-ply layers with eachlayer providing a specific function such as a separate vapor layer andthen a reinforcement layer.

Referring now to FIG. 41, structure 1000 is shown having a plurality oflayers as discussed above. In addition to another elastomeric layer 1800and inter-ply layer 1750, another layer 2000 is added to securephotovoltaic element 1400 and to create a coating compatible surface. Asdiscussed above, more layers (not shown) may be added to meet specificapplications.

Different combinations of inter-ply, structural elements, flashingmembers, vapor retarders, mechanical support structures may be utilizedto provide the desired result and are considered to be within the scopeof the present invention. Elastomeric coatings may include but notlimited to the following:

Acrylic coatings: these coatings are typically white in color but can betinted any color and may be latex or acrylic resin polymer based. Ifused with concrete it is desirable to utilize a concrete primer.

Polyurethane or urethane coatings: one component moisture, water curedurethane polymers as well as two component catalysis cured urethanes maybe applied in one or two or more coat applications (i.e. base and finishcoat) and are available in a wide range of colors. Urethane coatingshave high tensile strength, are resistant to pooling water and manychemicals and once cured form a strong long-lasting waterproof andweatherproof surface that has superior long-term weatheringcharacteristics.

Asphalt-based coatings: asphalt-based waterproof coatings are foundeither as a solvent based or water-based emulsion type coating.Asphalt-based waterproof coatings are sometimes modified with differentpolymers and modifiers such as neoprene rubber to improve theirlong-term performance and adhesion to concrete or asphalt-basedsubstrates. Asphalt-based coatings may require a primer due to asphalt'sblack color and may need an additional white acrylic or urethanecoating.

Polyurea coatings: polyurea-based concrete waterproof coatings are madeof two components; an isocyanate compound in a resin blend with onlyamine-terminated components. Such coatings require special equipment tomix and spray. Polyurea and polyurethane hybrid blends have a slowersetting time and provide superior wetting of the concrete substrate.Other waterproofing coatings may be used and should be selected based onthe surface being protected as is known in the art. The coatings mayhave additional surface treatments such as mineral or ceramic granulesapplied to protect the top coating surface or to improve fire coderatings.

Solar electric or photovoltaic (PV) panels. There are basically twocategories of photovoltaic technologies commonly used to manufacturecommercial PV modules. The first technology utilizes relatively thickcrystals and includes solar cells made from crystalline silicon eitheras a single or polycrystalline wafer and can be integrated on rigid,semi-flexible or flexible panels. A second technology utilizes thin-filmproducts that typically incorporate very thin layers of photovoltaicactive material placed on glass, metal foil or plastic substrate.Thin-film modules are made by depositing photoelectric materials onstainless steel or polymer-based substrates and encapsulating the foilin rigid or flexible plastic polymers. The upper polymer cover surfaceis solar transparent. In general thin-film modules are more flexiblethan crystalline modules. The semi conductor materials used in thethin-film modules include, but not limited to, amorphous silicon (a-Si),copper indium diselenide (CIS), and cadmium telluride (CdTe). Newerphotovoltaic technologies appearing on the market today usedye-sensitized solar cells which contain a dye impregnated layer oftitanium dioxide to generate a voltage rather than the semiconductingmaterials used in most solar cells. Another developing technology isbased on nanotechnology photovoltaics. A photovoltaic system isconstructed by assembling a number of individual collectors calledmodules which are electrically and mechanically connected in an array.

Photovoltaic elements produce electricity by exposure to sunlight andneed to be wired according to manufacturer specifications. Allphotovoltaic elements utilized by the present invention are commerciallyavailable units or modules manufactured to specifically incorporate thedesign elements described and are wired according to the manufacturerspecifications. The number of photovoltaic elements utilized will dependupon such factors as available space and power requirements as is knownin the art

In the thermally regulated embodiments according to the presentinvention, the apparatus required to circulate the liquid within thetubes may be remotely located or adjacent to the installation as isknown in the art. Any exposed connections should be sealed by the topelastomeric coat or other waterproofing and weatherproofing methods asis known in the art.

Although the instant invention has been described in relation toparticular embodiments thereof, many other variations and modificationsand other uses will become apparent to those skilled in the art.

1. A method of protecting a roof using elastomeric weatherproofingbuilding material coatings and photovoltaic modules to provide acontinuous, seamless, waterproof, weatherproof and electricallygenerating surface comprising the steps of: selecting a roof to betreated; coating said roof surface with a first elastomeric coatingwherein said roof is protected from environmental damage; embedding atleast one photovoltaic module within said first elastomeric coatingwherein said photovoltaic module is sealed therein; applying a secondelastomeric coating over said first elastomeric coating further sealingsaid roof and said at least one photovoltaic module therein.
 2. Themethod of layering a structure protecting a roof using elastomericweatherproofing building material coatings and photovoltaic modules toprovide a continuous, seamless, waterproof, weatherproof andelectrically generating surface according to claim 1 wherein said firstand second elastomeric coats coatings are individually selected to matcha specific application.
 3. The method of layering a structure protectinga roof using elastomeric weatherproofing building material coatings andphotovoltaic modules to provide a continuous, seamless, waterproof,weatherproof and electrically generating surface according to claim 1wherein said first and second elastomeric coats coatings are selected tobe the same material.
 4. A method of layering a roof using elastomericweatherproofing building material coatings and photovoltaic modules toprovide a continuous, seamless, waterproof, weatherproof andelectrically generating surface comprising the steps of: selecting aroof surface to be treated; coating said selected roof surface with afirst elastomeric coating; positioning at least one photovoltaic moduleon said first elastomeric coating; and applying a second elastomericcoat coating over said first elastomeric coat coating and around aperimeter of said photovoltaic module wherein said photovoltaic moduleis sealed therein wherein said roof surface is sealed from environmentalhazards.
 5. The method of layering a roof using elastomericweatherproofing building material coatings and photovoltaic modules toprovide a continuous, seamless, waterproof, weatherproof andelectrically generating surface according to claim 4 further comprisingthe step of adhering said at least one photovoltaic module with anadhesive.
 6. The method of layering a roof using elastomericweatherproofing building material coatings and photovoltaic modules toprovide a continuous, seamless, waterproof, weatherproof andelectrically generating surface according to claim 5 wherein saidadhesive is a fabric covered self adhesive tape.
 7. The method oflayering a roof using elastomeric weatherproofing building materialcoatings and photovoltaic modules to provide a continuous, seamless,waterproof, weatherproof and electrically generating surface accordingto claim 5 wherein said adhesive is applied to a bottom portion of saidat least one photovoltaic module offsite.
 8. The method of layering aroof using elastomeric weatherproofing building material coatings andphotovoltaic modules to provide a continuous, seamless, waterproof,weatherproof and electrically generating surface according to claim 5wherein said adhesive is applied to a bottom portion of said at leastone photovoltaic module by an installer at an installation site.